Micro-optic adapters and tips for surgical illumination fibers

ABSTRACT

A microstructure optical adapter or tip according to the present disclosure may incorporate precision micro structure optical components engaging the input or output end of light energy delivery devices for customized light delivery of the light energy. The incorporation of precision micro structure optical components in injection molded plastic or glass parts will allow for inexpensive modification of the output light while also serving to protect the end of the illumination device. The micro structure optical components may also be incorporated in an adapter to tailor the light energy to the subsequent device.

CROSS-REFERENCE

The present application is a continuation of U.S. patent applicationSer. No. 14/958,716 (Attorney Docket No. 40556-711.304) now U.S. Pat.No. ______, filed on Dec. 3, 2015, which is a continuation of U.S.patent application Ser. No. 14/063,910 (Attorney Docket No.40556-711.303) now U.S. Pat. No. ______ filed on Oct. 25, 2013, which isa continuation of U.S. patent application Ser. No. 13/605,891 (AttorneyDocket No. 40556-711.302) now U.S. Pat. No. 8,594,472 filed Sep. 6,2012, which is a continuation of U.S. patent application Ser. No.12/349,358 (Attorney Docket No. 40556-711.301) now U.S. Pat. No.8,285,093 filed Jan. 6, 2009, which is a continuation of U.S. patentapplication Ser. No. 11/796,498 (Attorney Docket No. 40556-711.201) nowU.S. Pat. No. 7,474,820 filed Apr. 26, 2007, which is a non-provisionalof, and claims the benefit of U.S. Provisional Application No.60/795,986 (Attorney Docket No. 40556-711.101) filed Apr. 27, 2006; theentire contents of each of which is incorporated herein by reference.

FIELD OF THE INVENTIONS

The inventions described below relate to the field of surgicalillumination and more specifically to Micro Structured Optical adaptersand end caps for surgical illumination.

BACKGROUND OF THE INVENTION

Illumination devices, such as fiber optics, have many applications andgenerally employ conventional methods such as reflective surfaces ortotal internal reflection to deflect or focus the light energy. Somedevices also have modifications of the distal end or tip geometry togenerate focused or defocused beams. Tip modifications for opticalfibers are typically produced by polishing or grinding of the fiber tipor the end of a bundle of fibers. Conventional techniques have alsoincluded use of high temperatures such as with use of a fusion splicerto create ball tip structures generated by melting the core of anoptical fiber.

The limitation of these techniques is that they require accuratemanipulation of the device resulting in a modified section which is thenleft unprotected. For optical fibers, the techniques for polishing ormanipulating the tip are costly, time consuming and result in a fragileend product. The techniques available for creating lensing surfacesusing the device itself are limited and generate limited optical outputlensing options.

Illumination devices such as laser fibers for medical use are frequentlyused either in direct contact with tissue or in a fluid medium. In thesesettings, focus of the laser beam emanating from the fiber is difficultto control due to the similar indices of refraction of the various mediaand the fiber.

What is needed is a versatile technique for terminating illuminationdevices, or for adapting illumination devices to optimize the lightenergy and provide desired optical performance.

SUMMARY OF THE INVENTION

A micro structured optical adapter or tip according to the presentdisclosure may incorporate optical lensing structures to be placed overthe end of any suitable illumination device such as fiber optic laserdelivery devices. The cap or adapter may incorporate micro structuredoptical components such as for example gratings, prisms and or diffusersto operate as precision optics for customized delivery of the lightenergy. These components may be formed as injection molded plastic orglass parts to allow for inexpensive modification of the output lightand also serve to protect the end of the device, such as a cleaved fiberoptic bundle. The micro structured optical components may also beincorporated in an adapter to tailor the light energy to the subsequentdevices. The micro structured optical components may also be used topolarize and/or filter the light energy entering or exiting theillumination device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cutaway view of a laser fiber and micro structure opticalend cap according to the present disclosure.

FIG. 2 is a cutaway view of an alternate micro structure optical end capaccording to the present disclosure.

FIG. 3 is a cutaway view of another alternate micro structure opticalend cap according to the present disclosure.

FIG. 4 is a cutaway view of a micro structure optical adapter accordingto the present disclosure.

FIG. 5 is a cutaway view of a micro structure optical adapter and endelement according to the present disclosure.

FIG. 6 is a cross section view of the micro structure optical adapter ofFIG. 5 taken along A-A.

FIG. 7 is a cross section view of the micro structure optical adapter ofFIG. 5 taken along B-B.

FIG. 8 is a side view of a micro structure optical adapter and an endelement according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1 medical illumination fiber 10 engages an end cap such as cap14 to form an optical path with one or more micro structure opticalsurfaces such as inner optical surface 14A or outer optical surface 14Band or one or more air gaps such as gap 16 and or index matchingmaterial to control light 12. Any suitable surface such as inner anouter optical surfaces 14A and 14B or a portion of an inner or outersurface may be formed to include micro structure optical structures suchas structure 18A and or 18B thereon. Cap 14 may be made of glass,plastic or any other suitable material and may be sized to enable bore13 to frictionally engage optical fiber 10.

Input and or output micro optical structures such as structure 18A orstructure 18B may adopt any suitable configuration to accomplish one ormore of the functions of diffracting, deflecting, refracting orpolarizing light passing through the micro structure optical component.Such structures individually or in combination may be used to adjust theintensity and or the phase of the light energy similar to holographicfilm which may also be used.

Referring now to FIG. 2 illumination fiber 10 includes a lightmanagement cap such as cap 22 engaging end 24 of fiber 10. A lightmanagement cap according to the present disclosure such as cap 22 mayengage a fiber along engagement zone 21 mechanically, frictionally, orusing adhesives or any other suitable technique. Matching zone 23 of cap22 may be an air gap, or be filled with any suitable material such asadapter material 26 to achieve a suitable index transition betweenillumination fiber 10 and cap 22. Body zone 25 of cap 22 may be composedof solid cap material, or any suitable combination of air gaps orinserted components may also be used. Cap zone or output zone 27 may beformed in any suitable shape and may include microstructure such asstructures 18A and 18B to achieve desired output light management.

Referring to FIG. 3, light management cap 30 may include one or morechambers or other inserted structures to control light emanating fromillumination fiber 10. Chamber 32 may be filled with air or othersuitable material to achieve the desired light management. Incidentsurface 33 and outlet surface 35 of chamber 32 may be formed to have anysuitable surface characteristics such as surfaces 18A and 18B.

Referring now to FIG. 4, fiber adapter 36 includes an input bore 36A andan output bore 36B. Input bore 36A may adopt any suitable geometry toengage a first element such as illumination fiber 10 having a dimension34 and couple it to a second element such as fiber 20 having a dimension38. Dimensions 34 and 38 may be the same or different. Surfaces 37 and39 may be formed to have any suitable surface characteristics such asmicro structure optical surfaces 18A and 18B. A fiber adapter such asadapter 36 may also include one or more energy conforming elements suchas elements 40 and 42. Elements 40 and 42 may be solid or hollow withone or more surfaces including conventional shapes and or microstructure optical components. Adapters such as adapter 36 may also beused to connect an illumination fiber to an end element having anysuitable dimensions and geometry. End elements may have round, oval,rectangular, and polygonal or any other suitable cross section. Adapterssuch as adapter 36 may also incorporate a flexible center section orlight conduit such as center section 36C, thereby allowing element 20 tobe oriented in any position relative to illumination fiber 10. Thisallows element 20 to be oriented in a selected direction to accommodateselected use or selected mounting on auxiliary equipment. Center section36 c may be fabricated from optical fibers, silicone or other suitableflexible material. Elements 40 and 42 may serve to couple light into andout of this flexible section, for example, as suitably designed lenses.

Flexible adapter 36 may be constructed entirely of flexible material,for example, injection molded silicone, or it may be fabricated as anassembly including an input connector, flexible light conduit, andoutput connector using suitable fabrication and assembly techniques. Aflexible adapter may be incorporated as a permanent component of anillumination input, for example as part of a fiber optic light guidecable using adhesive or other suitable joining technique, therebyallowing end elements to be changed without fear of disengaging theadapter from the illumination input. Conversely, a flexible adapter maybe incorporated as a permanent component of an end element orillumination device using suitable joining techniques, thereby allowingdifferent end element devices to be used with the same illuminationinput without fear of disengaging the adapter or without the added stepof replacing an adapter for each new device to be used.

Referring to FIG. 5, FIG. 6 and FIG. 7 adapter 44 engages a generallyround illumination fiber at receptacle 54. Receptacle 56 engages device46 having a generally rectangular cross-section. As discussed abovesurface 48 of device 46 may incorporate suitable micro structure opticalcomponents to enhance light coupling into device 46. Facets such asfacet 50 may also incorporate micro structure optical components orother coatings such as polarizing coating 52. Adapter 44 may alsoinclude a flexible middle portion that conducts light, thereby allowingdevice 46 to be oriented in any direction relative to an illuminationinput at receptacle 54.

Polarized coating 52 emits polarized light to optimize viewing of site60. Use of a complementary polarization microstructure or coating suchas microstructure 58 on lens 62 permits any suitable light receiver suchas camera 64 to receive only properly polarized light 66 and rejectother reflected light such as light 68 thus minimizing distractingreflections and glare.

Referring now to FIG. 8, adapter 69 is coupled to end element 70. Endelement 70 may include one or more light emission facets such as facets72, 73, 74 and 76 for output of light energy. Input surface 71 of endelement 70 may incorporate polarizing microstructure 71A. Each lightemission facet may have a polarizing microstructure or coating such asmicrostructures 72A, 73A, 74A and 76A, and two or more of the lightemission facets may have similarly oriented polarization. Controllingthe orientation of a polarized input may allow light to be emitted fromone or more facets having complimentary polarization. For example,adapter 69 may be made to rotate relative to end element 70 such thatthis rotation causes separate polarizing structures formed in adapter 69to line up with at least part of input surface 71, without polarizingmicrostructure 71A, such that light emits from complementarypolarization facet 72 at zero degrees of relative rotation of adapter69, but that light emits from separate complimentary polarization facet74 at 90 degrees of relative rotation of adapter 69.

End element 70 or any adapter or end cap may also be formed to includeone or more constituent elements to cause end element 70 to filter andor polarize the light energy input into end element 70 and cause emittedlight 78 to have a desired frequency or combination of frequencies andor polarization orientation. End element 70 may also be treated to causeits constituent element or elements to operate as a light filterenabling chromatography. End element 70 may include co-molded element 73that splits the incoming light such that a fraction of the light exitsfacet 72, which may have a filtering microstructure or coating 72A, afraction exits facet 74 incorporating redirecting microstructure prism74A, and a fraction exits normally through facet 76.

A micro structured optical cap may also contain one or more gas or airfilled chambers that allows the light to refract prior to reaching thetissue or fluid. A cap or adapter may also operate as a filter to pass adesired frequency or frequencies of light by selecting the gas fillingand or additives to be incorporated with the material of the cap oradapter.

A micro structured optical adapter or tip according to the presentdisclosure may use micro structured optical components to manage oradapt the light output of an illumination fiber. By making a device oradapter consisting of one or more micro structured optical componentsinjection molded onto a flat window, which can be attached to a standardfiber, the light output of the illumination fiber may be controlledwithout the need to polish the tip of the fiber.

In another aspect, one or more surfaces in the optical path of anadapter or cap may include a predetermined micro structured opticalcomponents. Different optical light output shapes may be achieved bycreating specific microstructure surfaces or patterns.

It is also possible to apply the microstructure technology to deflectlight as well as focus it into a particular shape. Microstructures maybe applied to the back and or the front of a refractive element todeflect the beam as well as shape it. Microstructure surfaces may alsobe combined with one or more air gaps and or conventional surfaceshaping to achieve desired optical performance.

Other potential configurations can be designed to engage and secure thecaps to the end of a fiber. This can be done using adhesive with indexmatching glue, or it could be done mechanically leaving an air space.The cap could be made from glass or plastic, or other suitable opticalmaterial.

A micro structure optical adapter according to the present disclosuremay be used to adapt any suitable illumination energy from aconventional round source such as an optical fiber or fiber bundle to anend element having any suitable cross section. This adapter may beflexible, allowing the user to preferably orient the end elementrelative to the source. The use of micro structure optical componentsand or conventional diffraction and or refraction elements may permitoptimal transfer of light energy from the fiber to the end element.These structures can be part of an injection mold or may be applied as aseparate film.

In a still further aspect of the present disclosure one or more surfacesin an illumination path may be polarized using any suitable techniquesuch as an injection molded micro structure optical component, thin filmcoating or other. Use of polarized light in a surgical environment mayprovide superior illumination and coupled with the use of complementarycrossed polarized material on viewing devices such as video or stillcameras, surgical loupes, microscopes, face shields or surgeons glassesmay reduce reflected glare providing less visual distortion and moreaccurate color resolution of the surgical site.

Due to an expensive and complex process, standard fiber optic bundles donot preserve polarization. Therefore, polarized light that istransmitted through a fiber optic bundle will become depolarized. Theapplication of a tip device with polarization structures would stillallow polarized light to be delivered.

In a still further aspect of the present disclosure use of a microstructure optical tip or adapter incorporating filtering additives suchas dyes or structures such as for example diffraction gratings, mayproduce light of a selected frequency. The frequency of the light outputmay be selected to provide selective reflection and or absorption toenhance surgery, therapy and or diagnosis.

While polarizing and filtering components may be fabricated in adaptersand or tips that are subsequently applied to an illumination device,another further aspect of this disclosure is the fabrication of thesecomponents directly in the illumination device. As noted, optical fibersare very difficult to modify to form these components, but moderntooling and injection molding processes provide that capability, forexample, with plastic waveguides or light pipes. Facets may be formed inan injection molded illumination device wherein the facet face, whichmay normally act as a refraction surface, may be modified to includemicro structure optical components that perform polarization and orfiltering functions. For example, such structures may be molded into theinput face to polarize light as it enters the illumination device sothat the light exiting the device is polarized.

Furthermore, micro structure optical components may also be formed ofmetal or other suitable materials, e.g., beam splitters or polarizationgrids, then co-molded into a plastic illumination device. For example, abeam splitter co-molded in the center of a plastic light pipe may forcepart of an incoming light beam out of a facet with a green filtergrating molded in and part of the light beam out of a second facet witha red filter grating molded in. The user may simply reposition the lightpipe to use either color light for a particular purpose.

In typical application, an adapter may be disposed between a lightsource, such as a fiber optic light guide cable, and an end elementillumination device, such as a fiber optic light pipe or a plasticwaveguide or light pipe. A tip may be used instead of the adapter forcertain functions, for example, providing a polarizing tip to a standardfiber optic light pipe. The user may remove and replace adaptors andtips as needed for specific light output needs, but the process ofremoving and replacing adapters and tips may be troublesome, forexample, during a surgical procedure.

In another further embodiment, a polarization rotator such as ahalf-wave plate which can rotate polarized light by a predeterminedangle may provide different angles of polarization to be combined withmatching polarized facets on an end element device or polarized sectionsin a tip. Each facet or section might be directed in different visualangles or may have a filtering film applied. As the polarization rotatoris adjusted to a particular polarizing angle, polarized light travelsdown the end element to the facet or tip section that has a matchingpolarization. Light then exits from this matched output facet orsection, but not other facets or sections due to the polarizationeffect. This may be used to selectively illuminate certain areas of avisual field or to select certain filters for better visualization ofelements in a visual field. For example, in a surgical procedure, theadjustable polarizer could be adjusted so that light only shines out ofa tip section that provides filtered light suitable for visualization ofblood vessels, while a different setting on the adjustable polarizercauses light to shine out of a separate tip section that provides adifferent color of light suitable for visualization of nerves.

Thus, while the preferred embodiments of the devices and methods havebeen described in reference to the environment in which they weredeveloped, they are merely illustrative of the principles of theinventions. Other embodiments and configurations may be devised withoutdeparting from the spirit of the inventions and the scope of theappended claims.

We claim:
 1. A method for illuminating a surgical field, said methodcomprising: providing an optical fiber and an optical tip; coupling theoptical fiber with the optical cap; delivering light form the opticalfiber to the optical tip; and illuminating the surgical field with lightfrom the optical tip.
 2. A surgical illumination system for illuminatinga surgical field, said system comprising: an optical fiber; and anoptical tip coupled to the optical fiber, wherein light passes throughthe optical fiber to the optical tip, and wherein the light is directedfrom the optical tip to the surgical field.